Powered door unit with improved mounting arrangement

Abstract

A powered actuator for moving a motor vehicle closure panel from a closed position to an open position and method of construction thereof. Powered actuator includes an electric motor configured to rotate a driven shaft and a gearbox coupled to the driven shaft. An extensible member extends through the gearbox to a proximal end on one side of the gearbox for attachment to one of a vehicle body or the closure member and to a distal end on an opposite side of the gearbox. Extensible member is configured to move between retracted and extended positions in response to rotation of the driven shaft. A contamination cover enshrouds the extensible member between the gearbox and the distal end of the extensible member. Contamination cover moves between an axially extended state and an axially retracted state while the extensible member moves between the respective retracted position and the extended position.

What is claimed is: 
     
       1. A powered actuator for moving a closure panel of a motor vehicle between a closed position and an open position, comprising:
 an electric motor configured to rotate a driven shaft; 
 a gearbox coupled to said driven shaft; 
 a gearbox housing enclosing the gearbox; 
 an extensible member extending through said gearbox and having a proximal end on a first side of the gearbox and a distal end on a second side of the gear box, said first side being opposite said second side, said distal end being configured to be pivotably coupled to one of a vehicle body or the closure panel, said extensible member being configured to move from said first side and from said second side of said gear box between a retracted position, corresponding to the closed position of the closure panel, and an extended position, corresponding to the open position of the closure panel, in response to rotation of the driven shaft; and 
 a coupling configured to couple the gearbox housing to the closure panel. 
 
     
     
       2. The power actuator of  claim 1 , wherein the gearbox housing has a first end for receiving the distal end of the extensible member and an opposite second end for receiving the proximal end of the extensible member, wherein the coupling is a pivotal coupling positioned between the gearbox housing and the closure panel and is connected to the second end of the gearbox housing, wherein the coupling is configured for pivoting movement in response to the closure panel moving between the open position and closed position. 
     
     
       3. The power actuator of  claim 2 , wherein the closure panel has an inner panel and an outer panel defining an inner cavity, wherein the pivotal coupling includes a mount bracket configured for fixed attachment to an inner shut face panel extending between the outer panel and the inner panel of the closure panel, and for pivotal attachment to the gear box housing such that the power actuator is pivotable within the inner cavity. 
     
     
       4. The power actuator of  claim 3 , wherein the mount bracket comprises a plate for fixed attachment with the inner shut face panel, the plate comprising an aperture for receiving the extensible member, wherein the aperture is aligned with a port provided in the inner shut face panel, the port for receiving the extensible member. 
     
     
       5. The power actuator of  claim 4 , wherein the mount bracket has a first flange for pivotal attachment to the upper side of the gearbox housing and a second flange for pivotal attachment to the lower side of the gear box housing. 
     
     
       6. The power actuator of  claim 5 , wherein the plate, the first flange, and the second flange form a U-shape. 
     
     
       7. The power actuator of  claim 5 , wherein the upper side of the gearbox housing has an upper boss and the lower side of the gearbox housing has a lower boss, said upper boss being pivotably coupled to said upper flange by an upper pin, said lower boss being pivotably coupled to said lower flange by a lower pin, said upper pin and said lower pin being coaxially aligned with one another. 
     
     
       8. The power actuator of  claim 2 , wherein the coupling includes an upper pivotal attachment for connection to an upper side of the gear box housing and a lower pivotal attachment for connection to a lower side of the gearbox housing. 
     
     
       9. The power actuator of  claim 1 , wherein the coupling includes a mount bracket attached to an inner shut face panel extending between an outer panel and an inner panel of the closure panel. 
     
     
       10. The power actuator of  claim 9 , wherein the inner panel and the outer panel defining an inner cavity of the closure panel, and wherein the power actuator is pivotable within the inner cavity. 
     
     
       11. The power actuator of  claim 10 , wherein the mount bracket defines a clearance opening for receipt of the extensible member to move in unobstructed pivotal movement therein. 
     
     
       12. The power actuator of  claim 11 , wherein the mount bracket is generally U-shaped. 
     
     
       13. The power actuator of  claim 1 , wherein the gearbox is configured to rotatably support a nut operably driving the motor shaft, wherein the extensible member is operably coupled to and extending through the nut for extension and retraction in response to rotation of the nut by the electric motor. 
     
     
       14. The power actuator of  claim 13 , wherein the nut is rotatably support within the gear box housing by at least one bushing. 
     
     
       15. The power actuator of  claim 14 , wherein the nut is configured as an elongated nut tube, wherein more than one bushing is interposed between the nut tube and the gear box housing. 
     
     
       16. The power actuator of  claim 1 , wherein in the extended position, a majority of the extensible member is extended outside of an interior cavity of the closure panel. 
     
     
       17. The power actuator of  claim 1 , further comprising a first cover having a first end region coupled to a first side of the gearbox housing and a second end region covering the proximal end of the extensible member, the first cover receiving at least a portion of the extensible member therein, wherein the first cover is moveable between an extended state, whereat the closure panel is in the closed position, and a retracted state, whereat the closure panel is in the open position, in response to movement of the extensible member. 
     
     
       18. The power actuator of  claim 17 , wherein the first cover has a plurality of cover sections moveable relative to one another in response to movement of the extensible member. 
     
     
       19. The power actuator of  claim 18 , wherein the plurality of cover sections are configured for movement in telescoping relation with one another, wherein at least some of the cover sections are telescopically nested with one another while the first cover is in the retracted state. 
     
     
       20. The powered actuator of  claim 17 , further including a second cover having a first end region coupled to a second side of the gearbox housing opposite the first side and a second end region coupled to the distal end of the extensible member, the second cover receiving at least a portion of the extensible member therein, wherein the second cover is moveable between an extended state, whereat the closure panel is in the open position, and a retracted state, whereat the closure panel is in the closed position, in response to movement of the extensible member.